Cool Air for the EcoBoost. F-150 Intercooler R&D, Part 4: Intercooler Ducting
In our last entry, we finished the 3D-printing process for our first prototype intercooler. Our team then started the tedious work of modeling all the features we plan to implement and finalizing the details of our intercooler design. During this process, a new idea emerged that would both improve the performance of our cooler and set our kit apart from others.
Let's dive right in!
F-150 Intercooler Shrouding Fabrication
The footprint of our intercooler core is far larger than that of the stock intercooler. Because of this, it is likely that the airflow supplied by the stock bumper duct is not reaching the entire surface area of our cooler. To combat any issues with loss of airflow, we decided to experiment with some ducting to direct air through the core.
We began the fabrication process with a few old-school techniques; our engineers broke out the template material and a measuring device and started cutting out some ideas.
The trial-and-error process began, as we carefully adjusted the templates until they began to take form.
Once completed in cardboard, these designs were translated to sheet aluminum for final test fitting. First, check out the horizontally mounted duct that seals the top of the intercooler.
The back side of this piece reveals a couple mounting points to attach to the intercooler and other shrouding pieces.
We are also lining the edges with weather-stripping to prevent scraping, damage, or vibrational noises. Next, we repeated the same process but for the ducting on the sides of the intercooler, which also had potential airflow issues. Check out our first prototype iteration:
Two mounting points on each shroud will attach directly to the intercooler end tank. The single hole towards the point will attach to the horizontal shroud on the top of the cooler.
Here is our finished prototype kit:
It will be interesting to see the impact of our additional ducting on actual heat transfer.
Coming Up - 3D Models
Check back in a few weeks for the presentation of our 3D models showing the final intercooler prototype design.
Thanks for reading!